ByRanu Chatterjee Garima Chauhan Subhra Naskar Nupur Grover Rakesh Ranjan Behra

What is lean manufacturing???

Lean Manufacturing A way to eliminate waste and

improve efficiency in a manufacturing environment Lean focuses on flow, the value stream and eliminating muda, the Japanese word for waste Lean manufacturing is the production of goods using less of everything compared to traditional mass production: less waste, human effort, manufacturing space, investment in tools, inventory, and engineering time to develop a new product

Lean and Just-in-Time

Lean was generated from the Just-in-time (JIT) philosophy of continuous and forced problem solving
Just-in-time is supplying customers with exactly what

they want when they want it With JIT, supplies and components are pulled through a system to arrive where they are needed when they are needed

What is Waste?
Waste is anything that happens to a product that does not add value from

the customers perspective

Products being stored, inspected or delayed, products waiting in queues,

and defective products do not add value

Types of Wastes
Overproduction producing more than the customer orders or producing early. Inventory of any kind is usually waste.

Queues idle time, storage, and waiting are wastes

Transportation moving material between plants, between work centers, and handling more than once is waste Inventory unnecessary raw material, work-in-process (WIP), finished goods, and excess operating supplies

rigins
Lean Manufacturing is sometimes

called the Toyota Production System (TPS)

Toyota Motor Companys Eiji Toyoda

and Taiichui Ohno are given credit for its approach and innovations
Example Boeing Mfg.

Advantages
Increased overall productivity

Disadvantages
Depends on suppliers that can provide products for the manufacturing process dependably and without interruption lean pushes people out of their comfort zone in the name of eliminating waste and adding valuestart have feelings of discomfort , stress

Inventory storage management is decreased with its costs

Defect free products

Improved quality

How People Benefit from Lean

Element
Communication

Traditional
Slow & Uncertain

Lean
Fast & Positive

Improveme nt
Quality & Coordination

Teamwork

Inhibited

Enhanced

Effective Teams

Motivation

Negative, Extrinsic

Positive, Intrinsic

Strong Motivation

Skill Range

Narrow

Broad

Job Enrichment

Supervision

Difficult and Fragmented

Easy & Localized

Fewer Supervisors

How Customers Benefit from Lean

Element
Response Customization Delivery Speed Delivery Reliability

Traditional
Weeks Difficult Weeks-Months Erratic

Lean
Hours Easy Days Consistent & High

Improvement
70-90% Competitive Advantage 70-90% Up to 90%

Delivery Quantities
Quality

Large Shipments
Erratic

JIT as Required
Consistent & High

Locks in JIT Customers

Delighted Customers